RIDGIDRAIN ADVANCED DRAINAGE SYSTEM RIDGIDRAIN (HDPE) 150 MM TO 900 MM PIPES AND COUPLERS

Transcription

1 Polypipe Ltd t/a Polypipe Civils Charnwood Business Park North Road Loughborough Leicestershire LE11 1LE Tel: Fax: /H068 website: Product Sheet 6 RIDGIDRAIN ADVANCED DRAINAGE SYSTEM RIDGIDRAIN (HDPE) 150 MM TO 900 MM PIPES AND COUPLERS Page 1 of 12 HAPAS Certificate This HAPAS Certificate Product Sheet (1) is issued by the British Board of Agrément (BBA), supported by Highways England (HE) (acting on behalf of the Overseeing Organisations of the Department for Transport; Transport Scotland; the Welsh Assembly Government and the Department for Infrastructure, Northern Ireland), the Association of Directors of Environment, Economy, Planning and Transport (ADEPT), the Local Government Technical Advisers Group and industry bodies. HAPAS Certificates are normally each subject to a review every three years. (1) Hereinafter referred to as Certificate. This Certificate relates to Ridgidrain (HDPE) 150 mm to 900 mm Pipes and Couplers, a range of high density polyethylene (HDPE) pipes (perforated and unperforated) and couplers for use as filter and carrier pipes for highway drainage. CERTIFICATION INCLUDES: factors relating to compliance with Building Regulations where applicable factors relating to additional non-regulatory information where applicable independently verified technical specification assessment criteria and technical investigations design considerations installation guidance regular surveillance of production formal three-yearly review. KEY FACTORS ASSESSED Strength the pipes and couplers have adequate strength to resist loads associated with installation and service (see section 6). Performance of joints the products will remain watertight under normal service conditions (see section 7). Maintenance the products may be cleaned using standard techniques (see section 10). Durability the products will have a service life in excess of 50 years (see section 11). The BBA has awarded this Certificate to the company named above for the products described herein. These products have been assessed by the BBA as being fit for their intended use provided they are installed, used and maintained as set out in this Certificate. On behalf of the British Board of Agrément Date of Third issue: 26 April 2018 Paul Valentine Technical Excellence Director Claire Curtis-Thomas Chief Executive Originally certificated on 23 October 2012 The BBA is a UKAS accredited certification body Number 113. The schedule of the current scope of accreditation for product certification is available in pdf format via the UKAS link on the BBA website at Readers are advised to check the validity and latest issue number of this Agrément Certificate by either referring to the BBA website or contacting the BBA direct. British Board of Agrément Bucknalls Lane Watford Herts WD25 9BA 2018 tel: clientservices@bbacerts.co.uk

2 Requirements In the opinion of the BBA, Ridgidrain (HDPE) 150 mm to 900 mm Pipes and Couplers, when used in accordance with the provisions of this Certificate, will meet or contribute to meeting the following requirements of the Manual of Contract Documents for Highway Works (MCHW) (1), Volume 1 Specification for Highways Works (SHW) and Volume 2 Notes for Guidance on the Specification for Highway Works. The general requirements for structured wall pipes and fittings are contained in the MCHW, Volume 1 SHW, Clause 518. Further information and guidance is given in the MCHW, Volume 3, Drawing Numbers F1 and F2. Additional site requirements may be included on particular contracts. (1) The MCHW is operated by the Overseeing Organisations: Highways England (HE), Transport Scotland, the Welsh Assembly Government and the Department for Infrastructure (Northern Ireland). Regulations Construction (Design and Management) Regulations 2015 Construction (Design and Management) Regulations (Northern Ireland) 2016 Information in this Certificate may assist the client, designer (including Principal Designer) and contractor (including Principal Contractor) to address their obligations under these Regulations. See sections: 1 Description (1.1 and 1.3 to 1.6) and 3 Delivery and site handling (3.6) of this Certificate. Technical Specification 1 Description 1.1 Ridgidrain (HDPE) 100 mm to 900 mm filter and carrier (perforated and/or unperforated) pipes, and 400 mm to 600 mm couplers, are manufactured from HDPE to the material specifications given in Tables 1 and 3 respectively. Ridgidrain (PP) 100mm to 375 mm couplers are manufactured from polypropylene with the specifications given in Table 2. Ridgidrain 750mm to 900mm double couplers are manufactured from HDPE to the material specification given in Table 4. Table 1 Material properties/specification for pipes 150 mm 900 mm diameter (polyethylene) Property Test method reference Specification Tensile properties BS EN ISO Sample 1B at 50 mm m MPa Oxygen induction time BS EN min Melt mass-flow rate BS EN ISO g (10 min) kg at 190 C Reference density BS EN ISO kgm -3 Heat reversion ISO C ± 2 C (pass) Table 2 Material properties/specification for couplers 150 mm 375 mm diameter (polypropylene) Property Test method reference Specification Tensile properties BS EN ISO Sample 1B at 50 mm m MPa Oxygen induction time BS EN min Melt mass-flow rate BS EN ISO g (10 min) kg at 230 C Reference density BS EN ISO kgm -3 Heat reversion ISO C ± 2 C (pass) Page 2 of 12

3 Table 3 Material properties/specification for couplers 400 mm 600 mm diameter (polyethylene) Property Test method reference Specification Tensile properties BS EN ISO Sample 1B at 50 mm m MPa Thermal stability (OIT) BS EN min Melt mass-flow rate BS EN ISO g (10 min) kg at 190 C Reference density BS EN ISO kgm -3 Heat reversion ISO C ± 2 C (pass) Table 4 Material properties/specification for rotationally moulded double couplers 750 mm 900 mm diameter (polyethylene) Property Test method reference Specification Tensile properties BS EN ISO Sample 1B at 50 mm m MPa Thermal stability (OIT) BS EN min Melt mass-flow rate BS EN ISO g (10 min) -1 5 kg at 190 C Reference density BS EN ISO kgm The pipes are structured-wall constructions and have a corrugated outer wall and smooth inner wall. The outer wall is coloured black and the inner wall blue, as standard, although other internal colours are available on request (1). (1) Further information can be obtained from the Certificate holder. 1.3 The 150 mm to 600 mm pipes can be manufactured either perforated or unperforated. Perforated pipes are available with the slots in the dwell between corrugations equally spaced around the circumference and offset symmetrically for alternate dwells along the pipe length (see Tables 5, 6, 7 and 8, and Figure 1). Alternatively, the slots are located on one half of the pipe only, and thus the permeable area is approximately halved. Table 5 Perforated pipe details fully perforated (production line A) internal pipe diameter slots per dwell rows of slots dwells per metre Slot length (range) Slot width (range) Permeable area (minimum) (mm 2 m -1 ) Table 6 Perforated pipe details fully perforated (production line B) internal pipe diameter slots per dwell rows of slots dwells per metre Slot length (range) Slot width (range) Permeable area (minimum) (mm 2 m 1 ) Page 3 of 12

4 Table 7 Perforated pipe details half perforated (production line A) internal pipe diameter slots per dwell rows of slots dwells per metre Slot length (range) Slot width (range) Permeable area (minimum) (mm 2 m -1 ) 150 2/1 (1) /1 (1) (1) Two slots or one slot in alternating dwells. Table 8 Perforated pipe details half perforated (production line B) internal pipe diameter slots per dwell rows of slots dwells per metre Slot length (range) Slot width (range) Permeable area (minimum) (mm 2 m 1 ) Figure 1 Details of perforations 1.4 The pipes are manufactured in nominal internal diameters of 150 mm to 900 mm, and to the dimensions shown in Table 9 and Figure 2. Table 9 Ridgidrain (HDPE) 150 mm to 900 mm Pipe dimensions internal pipe diameter, d1 Minimum ( internal pipe diameter external pipe diameter, d2 t1 minimum t2 minimum t3 minimum length (m) mass (kg m -1 ) (SN4) (SN6) (SN4) (SN6) Page 4 of 12

5 Figure 2 Ridgidrain (HDPE) pipe 1.5 The pipes are supplied with either two plain ends, or with one plain end and a welded integral socket. The integral socket is to the same profile as that of half a coupler for integral sockets of diameter 400 mm to 600 mm diameter. For the 750 mm to 900 mm diameters, the integral is formed as part of the corrugation process. Dimensions of integral sockets are given in Table 10 and details are shown in Figure 3. Table 10 Integral socket dimensions internal pipe diameter, d1 internal socket diameter, d3 socket depth L1 seal height, h (SN4) (SN6) (SN4) (SN6) Figure 3 Welded integral socket and couplers 1.6 The black polyethylene couplers, manufactured by the Certificate holder, are used for jointing the plain ended Ridgidrain (HDPE) 150 mm to 600 mm Pipes. The rotationally moulded HDPE double couplers are externally bought-in for 750mm and 900mm Pipes (see Table 11 for coupler dimensions and Figure 3). Page 5 of 12

6 Table 11 Coupler dimensions internal pipe diameter, d1 internal socket diameter, d3 external diameter, d4 length (L) seal height, h Sealing of the integral socket joints, and joints formed using couplers, requires rubber sealing rings supplied by the Certificate holder (see Figure 4). The rings are manufactured to BS EN : The seals must be fitted in accordance with the Certificate holder s installation instructions to ensure a watertight joint. Figure 4 Seals 600mm pipe seal 750 mm pipe seal 900mm pipe seal Page 6 of 12

7 2 Manufacture 2.1 The pipes are manufactured by a twin extrusion process, with the inner and outer skins extruded simultaneously one inside the other, and heat-welded together in one continuous process. The moulded pipes are cooled, perforated if required, and cut to length. Two production lines, A and B, are used to manufacture the pipes. 2.2 The 150 mm to 375 mm double couplers are injection moulded. The 400 mm to 600 mm couplers are made from two injection moulded half couplers, which are then welded together to form the completed coupler. The 750 mm to 900 mm couplers are rotationally moulded. 2.3 The integral sockets are made using one half coupler, which is spin welded on to the end of the pipe for pipes of diameter 400 mm to 600 mm. For the 750 mm and 900 mm integral socket, these are formed as part of the corrugation process. 2.4 As part of the assessment and ongoing surveillance of product quality, the BBA has: agreed with the manufacturer the quality control procedures and product testing to be undertaken assessed and agreed the quality control operated over batches of incoming materials monitored the production process and verified that it is in accordance with the documented process evaluated the process for management of nonconformities checked that equipment has been properly tested and calibrated undertaken to carry out the above measures on a regular basis through a surveillance process, to verify that the specifications and quality control being operated by the manufacturer are being maintained. 2.5 The management system of Polypipe Ltd t/a Polypipe Civils has been assessed and registered as meeting the requirements of BS EN ISO 9001 : 2015 and BS EN ISO : 2004 by BSI (Certificate Q06225 and EMS respectively). 3 Delivery and site handling 3.1 The pipe sizes up to 400 mm diameter are delivered to site packaged on wooden support frames, with five pipe lengths to the pack. Pipes of 450 mm diameter and greater are supplied loose. 3.2 Each pipe bears a label showing: the company name product code (1) product type Ridgidrain unperforated, perforated, half perforated job/pack number operator length the BBA logo incorporating the number of this Certificate. (1) The Ridgidrain (HDPE) product range has /1 at the end of the product code. 3.3 Handling, storage and transportation should be in accordance with the requirements of the MCHW, Volume When long-term storage is envisaged, the products must be protected from direct sunlight. If protection cannot be provided, consideration must be given to the effects of daily exposure to direct sunlight: up to 3 months negligible UV degradation but possible extreme surface temperatures of up to 80 C may cause some localised distortion 3 to 12 months may have significant effect on the impact resistance and physical properties over 12 months damage will occur unless protection provided. 3.5 The Certificate holder has the option of adding chemicals to provide enhanced UV stability on request, but this is outside the scope of this Certificate. Page 7 of 12

8 3.6 The pipes should be stored on a flat surface. Where they are delivered as loose lengths, they should not be stacked more than 4 m high. Care should be taken not to drop pipes or couplers on their ends, particularly during cold weather conditions. Assessment and Technical Investigations The following is a summary of the assessment and technical investigations carried out on Ridgidrain (HDPE) 150 mm to 900 mm Pipes and Couplers. Design Considerations 4 Use Ridgidrain (HDPE) 150 mm to 900 mm Pipes and Couplers (perforated or unperforated), comply with the requirements of the MCHW, Volume 1, Clause for the pipes, Clause for the couplers, and Clause for the drainage system. When installed in accordance with the recommendations given in this Certificate, the products are suitable for the collection and disposal of surface and sub-surface water. 5 Practicability of installation The products are designed to be installed by a competent contractor experienced with these types of products in highway works. 6 Strength 6.1 The pipes have a ring stiffness in excess of 6 kn m 2 in accordance with BS EN ISO 9969 : 2016 and a creep ratio of less than 4 kn m 2 in accordance with BS EN ISO 9967 : 2016, and have adequate resistance to static loads. Pipes of sizes 750 mm and 900 mm are also available in stiffness class SN The pipes have adequate resistance to impact loads to which they may be subjected during installation and in service. 6.3 The pipes can be used as an alternative to the plastic pipes for surface water drains listed in the MCHW, Volume 1, Table 5/1, and for safe bedding depth purposes may be assumed to have a standard dimension ratio (SDR) not greater than Performance of joints 7.1 Joints on filter pipes made from pipe and couplers without the rubber seals are not partially watertight, as defined in the MCHW, Volume 1, Clause When correctly made, joints constructed from pipe and couplers with rubber seals remain watertight when subjected to deflection and distortion, and comply with the MCHW, Volume 1, Clauses and (see section 13). 8 Water infiltration The slot area for the pipes exceeds the HE minimum requirement given in the MCHW, Volume 1, Clause of 1000 mm 2 per metre length (see Tables 5 to 8 of this Certificate). 9 Flow characteristics 9.1 The pipes will have the normal flow characteristics associated with polyethylene pipes. 9.2 Full-bore velocities are available from the Tables for the Hydraulic Design of Pipes, Sewers and Channels, Volume 2, 8th Edition by H R Wallingford and D I H Barr. The values are based on the Colebrook-White equation. An appropriate value of roughness coefficient should be selected when designing the drainage system. For new pipes, a value of mm is applicable, but for designs, a value of 0.6 mm is generally used. Page 8 of 12

9 10 Maintenance 10.1 The slots are designed to restrict the ingress of silt into the drains Access to the products for cleaning should be provided by conventional methods In common with other standard plastic drainage systems, toothed root cutters and rods with metal ferrules, as used with some mechanical clearing systems, could damage the products and should not be used Tests indicate that the pipes have adequate resistance to water cleansing using low pressure, high volume pressure jetting systems and rodding. 11 Durability In the opinion of the BBA, when used in the context of this Certificate, the material from which the products are manufactured will not significantly deteriorate and their anticipated life will be in excess of 50 years. 12 Reuse and recyclability The products are manufactured from polyethylene and polypropylene, which are recyclable. Installation 13 General 13.1 Ridgidrain (HDPE) 150 mm to 900 mm Pipes and Couplers must be installed in accordance with HE requirements and the MCHW, Volume 1, Clauses 502, 503, 518.8, and The pipes are installed using traditional drain-laying methods. The lengths in which the pipes are available and their lightness in weight are a significant advantage in handling and installation. Jointing of the pipes is achieved easily The perforated and unperforated pipes and couplers must be protected against damage from construction traffic Completed drainage systems should be tested in accordance with BS EN 1610 : 2015 to ensure they are functioning correctly. 14 Procedure 14.1 For typical laying, trench and backfilling specification details, reference should be made to Figure 5 and the MCHW, Volume 3, Drawing Nos F1 (Type T and S) and F2 (Type G, H and I) The pipes are cut easily using conventional hand tools, and should be cut square between the corrugations For a watertight joint, the pipe ends and socket/coupler should be cleaned and a rubber seal fitted externally between the first and second corrugation in the pipe. The seal and inside of the socket/coupler should be lubricated and the pipe pushed fully home to the central register, either by hand or using a lever if necessary Care should be taken during backfill to maintain the line and level of the pipelines. If necessary, the pipe should be restrained to prevent uplift. Page 9 of 12

10 Figure 5 Trench and bedding details Technical Investigations 15 Tests 15.1 Tests were carried out to determine compliance with the MCHW, Volume 1, Clause 518.5, on: dimensional accuracy ring stiffness to BS EN ISO 9969 : 2016 creep ratio to BS EN ISO 9967 : 2016 impact strength at 0 and 23 C to BS EN 1411 : 1996 with a d25 striker of 1.0 kg mass water jetting WRc method Tests were carried out on joined pipes to establish compliance with the MCHW, Volume 1, Clause 518.7, on leaktightness of joints to BS EN 1277 : 2003, when subjected to diameter distortion and angular deflection from 0.5 to -0.3 bar. 16 Investigations 16.1 An assessment was made of data relating to: chemical resistance flow capacity practicability of installation material properties resistance to rodding and jetting resistance to cyclic loading The manufacturing process was evaluated, including the methods adopted for quality control, and details were obtained of the quality and composition of the materials used. Page 10 of 12

11 Bibliography BS EN : 1996 Elastomeric seals Material requirements for pipe joint seals used in water and drainage applications Vulcanized rubber BS EN 728 : 1997 Plastics piping and ducting systems Polyolefin pipes and fittings Determination of oxidation induction time BS EN Plastics piping systems Thermoplastics piping systems for buried non-pressure applications Test methods for leaktightness of elastomeric sealing ring type joints BS EN 1411 : 1996 Plastics piping and ducting systems Thermoplastics pipes Determination of resistance to external blows by the staircase method BS EN 1610 : 2015 Construction and testing of drains and sewers BS EN ISO : 2012 Plastics Determination of tensile properties Test conditions for moulding and extrusion plastics BS EN ISO 1133 : 2005 Plastics Determination of the melt mass-flow rate (MFR) and the melt volume-flow rate (MVR) of thermoplastics BS EN ISO : 2012 Plastics Methods for determining the density of non-cellular plastics Immersion method, liquid pyknometer method and titration method BS EN ISO 9001 : 2015 Quality management systems Requirements BS EN ISO : 2004 Environmental management system Requirements BS EN ISO 9967 : 2016 Thermoplastics pipes Determination of creep ratio BS EN ISO 9969 : 2016 Thermoplastics pipes Determination of ring stiffness ISO : 1995 Structural wall thermoplastics pipes Oven test Manual of Contract Documents for Highway Works, Volume 1 Specification for Highway Works Manual of Contract Documents for Highway Works, Volume 2 Notes for Guidance on the Specification for Highway Page 11 of 12

12 Conditions of Certification 17 Conditions 17.1 This Certificate: relates only to the product/system that is named and described on the front page is issued only to the company, firm, organisation or person named on the front page no other company, firm, organisation or person may hold claim that this Certificate has been issued to them is valid only within the UK has to be read, considered and used as a whole document it may be misleading and will be incomplete to be selective is copyright of the BBA is subject to English Law Publications, documents, specifications, legislation, regulations, standards and the like referenced in this Certificate are those that were current and/or deemed relevant by the BBA at the date of issue or reissue of this Certificate This Certificate will remain valid for an unlimited period provided that the product/system and its manufacture and/or fabrication, including all related and relevant parts and processes thereof: are maintained at or above the levels which have been assessed and found to be satisfactory by the BBA continue to be checked as and when deemed appropriate by the BBA under arrangements that it will determine are reviewed by the BBA as and when it considers appropriate The BBA has used due skill, care and diligence in preparing this Certificate, but no warranty is provided In issuing this Certificate the BBA is not responsible and is excluded from any liability to any company, firm, organisation or person, for any matters arising directly or indirectly from: the presence or absence of any patent, intellectual property or similar rights subsisting in the product/system or any other product/system the right of the Certificate holder to manufacture, supply, install, maintain or market the product/system actual installations of the product/system, including their nature, design, methods, performance, workmanship and maintenance any works and constructions in which the product/system is installed, including their nature, design, methods, performance, workmanship and maintenance any loss or damage, including personal injury, howsoever caused by the product/system, including its manufacture, supply, installation, use, maintenance and removal any claims by the manufacturer relating to CE marking Any information relating to the manufacture, supply, installation, use, maintenance and removal of this product/system which is contained or referred to in this Certificate is the minimum required to be met when the product/system is manufactured, supplied, installed, used, maintained and removed. It does not purport in any way to restate the requirements of the Health and Safety at Work etc. Act 1974, or of any other statutory, common law or other duty which may exist at the date of issue or reissue of this Certificate; nor is conformity with such information to be taken as satisfying the requirements of the 1974 Act or of any statutory, common law or other duty of care. British Board of Agrément Bucknalls Lane Watford Herts WD25 9BA 2018 tel: clientservices@bbacerts.co.uk Page 12 of 12